Edge drive control means for tubular fabric calendering systems

ABSTRACT

The disclosure relates to apparatus for the finishing of tubular knitted fabric. The finishing treatment involves the usual spreading to width and steaming of the fabric, with or without calendering, and gathering of the treated fabric. In its general aspects, the equipment of the invention performs well known and conventional operations. In its specifics, however, the equipment incorporates significant improvements.

United States Patent 1 [Ill 3,875,624

Frezza Apr. 8, 1975 [54] EDGE DRIVE CONTROL MEANS FOR 2.727.378 l2/I955Cook 226/44 2.880,] [4 3/!959 Cohn et al 26/55 R UX TUBULAR FABRICCALENDERING 3.257.735 6/1966 Catalio 26/56 X SYSTEMS [75] Inventor:Robert Frezza, Carle Place, NY. FOREIGN PATENTS OR APPLICATIONS1.536.604 7/1968 France 226/44 [73] Asslgnee: Samcoe Holdmg Corporation,2|2,369 3/1924 United Kingdom............t.... 26/55 R Woodside, NY.i,|54,7l2 6/I969 United Kingdom 26/55 R [22] Filed: I973 PrimaryExaminer-Robert R. Mackey [2i Appl. No.2 348,068 Attorney, Agent, orFirm-Mandeville and Schweitzer 52 us. Cl 26/56; 226/44 ABSTRACT [5 l]Int. Cl. D06c 5/00 The disclosure Mates apparatus for the finishing of[53] Fi ld f Search 2 /55 55 C. 22 /4 tubular knitted fabric. Thefinishing treatment in- 3 43 volves the usual spreading to width andsteaming of the fabric, with or without calendering, and gathering 5References cu of the treated fabric. In its general aspects, the equip-UMTED STATES PATENTS ment of the invention performs well known andconventional operations. In its specifics, however, the

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EDGE DRIVE CONTROL MEANS FOR TUBULAR FABRIC CALENDERING SYSTEMS Althoughthe disclosure is directed to a plurality of inventive features, theclaims of this application are limited to improvements in means forcontrolling and positioning edge drive rolls for a tubular fabricspreader. In a finishing machine, as contemplated by the invention,tubular knitted fabric is caused to be passed over a spreading frame,which functions to distend the fabric laterally, typically whileeffecting longitudinal relaxation of the fabric. While the fabric isthus laterally distended and longitudinally relaxed, it is steamed, inaccordance with well known practices. To propel the fabric over thespreader frame, it is known to provide opposed, driven edge drive rollswhich engage opposite edges of the spreading frame through theinterposed layer of fabric.

Because excessive mechanical pressure on the fabric can result inundesirable marking of the fabric, and possibly even damage to itsstructure, the present invention provides a new and advantageous systemfor positioning the edge drive rolls, and accurately controlling theforce applied by such rolls to the fabric wall. The edge drive rolls aremounted on controllably moveable carriages, which are moveable toward oraway from the center line of the apparatus, typically by means ofthreaded shafts. The carriages are driven by the threaded shafts throughnuts, which threadedly en gage the shafts, and compressible springmeans, which are interposed between the nuts and the carriages.

The apparatus of the invention advantageously utilizes pressurecontrolled air motor means for driving the threaded shafts. This permitsthe system to be adjusted by air pressure control to cause stalling ofthe air motor in response to a predetermined contact pressure by theedge drive rolls. Resilient mounting of the roll carriages provides forconvenient visual indication of the amount of the applied pressure andalso accommodates passage of lumps or other enlargements without undulyincreasing the pressure applied to the fabric.

Resilient mounting of the edge drive rolls additionally provides ahighly simplified yet reliable arrange ment for effecting instantshut-down of the equipment in the event of a malfunction in the feedingof fabric onto the spreader frame. If the spreader frame is dislodgedfrom its normal position between the edge drive rolls, the rolls areurged inwardly by their resilient mountings, and such movement isutilized to advantage to actuate a safety control device to shut downthe equipment.

BACKGROUND AND SUMMARY OF INVENTION In the processing and finishingtreatment of tubular knitted fabric, it is conventional practice todirect the tubular fabric over an internal spreading device. Thisdistends the fabric laterally to a predetermined uniform width. Whilethe fabric is held in this condition, it is steamed to relax the fibersand enable the fabric to readjust to the laterally distended,geometrically uniform condition. The fabric then tends to retain thiscondition as it is delivered off of the spreading device. The thustreated fabric may then be passed between a pair of calender rolls, andsubsequently gathered in a convenient manner, as by folding or gatheringinto a roll.

In general, the procedures outlined in the foregoing paragraph are wellknown. The present invention thus is not directed to the finishingprocedure in a general sense, but is directed to more specificstructural and procedural aspects calculated to achieve increasedproduction rates along with a superior quality of production.

Where tubular knitted fabric is directed over an internal spreadingapparatus, it is of course desirable to provide facilities forpositioning and supporting the spreader from the exterior. This meansthat the spread ing apparatus is to be engaged and held in position byexternal supporting means acting through the interposed fabric. Inaddition, it is usually advantageous to utilize fabricengaging drivebelts in connection with the internal spreading apparatus, to assist inthe forwarding conveyance of the fabric over the spreader frame. Thedriving of such belts, and the supporting of the spreading frame,typically may be accomplished by the use of edge drive rolls, engagingthe frame at its edges and acting through the contacted edges of fabricto position the frame and frictionally drive the propeller belts.

As will be understood, supporting of the spreader frame and driving ofthe belts through the interposed fabric walls requires pressure to beplaced upon the fabric, and this gives rise to a pressure-markingproblem, especially in so-called sensitive fabrics. By way of minimizingsuch pressure-marking problems, the apparatus of the invention includesa new and advantageous control arrangement for automatically providingan optimum degree of edge pressure at the edge drive rolls, to affordadequate spreader frame support and propeller belt driving, without atthe same time causing excessive pressure marking of the fabric. Inconjunction therewith, the apparatus includes a simplified yet reliableand effective safety control, operative to shut down the entire line ifthere is a dislodgement of the spreader frame, indicating snagging ofthe fabric at the entry end of the frame, or other serious malfunction.

To advantage, the processing system of the invention includes amotor-driven, substantially tension-free feeding system for deliveringtubular knitted fabric to the upstream or the entry end of the spreaderframe. By providing greater uniformity of conditions in the fabricdirected onto the spreader frame, improved uniformity in the processedfabric delivered therefrom is achieved.

At the discharge end, the system of the invention may include a folderor roll-up batcher. in part, the invention relates to an improved formof roll-up batcher, which minimizes shut-down or slow-down intervalswhen a completed roll is removed and a new roll is started. To this end,the roll-up batcher mechanism of the invention provides an increaseddegree of automation in the cut-off and restarting procedures. The arrangement is such that an operator, stationed at the discharge end ofthe machine, need merely initiate a roll removal operation, after whichfabric cut-off and the re-startin g of another batch roll takes placerapidly and without further operator intervention. This has desirablesafety aspects, as well as providing for higher production by shorteningthe change-over interval.

RELATED APPLICATIONS An integral part of the present apparatus,contributing to its ability to achieve higher production rates withoutcomprising quality, is an improved steaming apparatus for applying steamto the laterally distended tubular knitted fabric as it passes over thespreader frame. The specific structural features of this steamer, byitself. form the subject matter of my related copending application Ser.No. 355,401. filed Apr. 30, 1973. entitled High Production Steamer."

For a better understanding of the above and other features of theinvention, reference should be made to the following detaileddescription of a preferred embodiment and to the accompanying drawings.

DESCRIPTION OF THE DRAWINGS FIG. IA and IB. taken together, constitute aside elevational view of the apparatus of the invention.

FIG. 2 is a back elevational view of a fabric infeed stand utilized inthe apparatus of FIG, lA-IB. as viewed generally at line 22 of FIG. 18.

FIG. 3 is a top plan view of a portion of the apparatus of FIG. 1A and1B, illustrating details of the spreader frame and edge drivearrangements therefor.

FIGS. 4 and 5 are enlarged. fragmentary top plan views illustratingdetails of edge drive pressure control means utilized in the apparatusof the invention.

FIG. 6 is an enlarged, fragmentary cross-sectional view taken generallyon line 6-6 of FIG. 3.

FIG. 7 is an enlarged, fragmentary view, partly in section. illustratingstructural details of the discharge end of the apparatus of FIG. lA-lB.

FIG. 8 is a fragmentary back elevational view of the apparatus of FIG.lA-lB, as viewed generally at line 8-8 on FIG. 7.

DESCRIPTION OF A PREFERRED EMBODIMENT Referring now to the drawings andinitially to FIGS. lA-IB, the reference numeral 10 applies generally toa fabricfeeding stage, which supports a supply 11 of unfinished, tubularknitted fabric 12. In the illustration. the supply 11 is in the form ofa roll. although it could as well be a truck or other supply container.The fabric I2 is delivered by the supply section to a spreading ordistending section 13, where the fabric is initially distended to apredetermined uniform width and arranged in a flat. two-layered form.The fabric then. passes through a steaming section 14, while still inits distended condition. and it is there subjected to the action of jetsof steam to warm and moisten the fibers of the fabric.

In the illustrated system. the fabric being discharged from thespreading section 13 passes through a calendering section 15 comprisingessentially a pair of nip rolls, which may be in pressure-bearingrelation or not, depending on the desired finishing procedure. Thethus-finished fabric advances to a gathering section 16, where it isaccumulated in a convenient manner and in batches of convenient size andweight. In the illustrated arrangement. the gathering section comprisesa roll-up batcher, arranged to collect the fabric in the form of a roll.and to sever the fabric and deliver a roll of finished material ofpredetermined length or weight and of uniform width.

Referring more particularly to FIG. 1B, the supply section 10 of theapparatus includes an appropriate frame structure 17 arranged torotatably support a supply roll 11 by means of arms 18. The arms 18,which normally are supported in operative positions by latch arms 20,are arranged to be folded in close to the frame 17, about pivots 19, toaccommodate other forms of fabric supplies, such as containers.

Supply fabric 12 leaving the roll 11 advantageously is first directedupwardly about an idler roll 21, and then downwardly underneath andaround a second idler roller 22. This provides a broad expanse of clothconveniently accessible for visual inspection by the machine operator.

In the illustrated system. the supply fabric 12, after passing the idlerroller 22, is guided over and around a driven feed roller 23. Inaccordance with well known principles, the feed roller 23 may beprovided with a high friction surface so as to have a suitablefrictional engagement on the fabric surface. After passing around thefeed roller, the fabric travels downwardly, under and around a floatingcontrol roller 24 and thence upwardly and around an idler roll 25. Aswill be observed. the geometric relationship of the several rollers22-24 provides for the fabric to be in contact with the feed roller 23over a substantial arc of its circumference for good feeding contact.

In the illustrated apparatus, the feed roller 23 is driven by a chain 26from a variable speed electric motor 27. The operating speed of themotor 27 is controlled by a rotary control device 28, which senses thevertical position of the floating roller 24 to effect an increase inmotor speed, as the floating roller tends to rise, and to effect aslow-down of the motor if the floating roller tends to move to a lowerposition. This provides a constantly modulating speed control over theinfeeding of the fabric.

With reference to FIG. 2, the floating roller 24 is shown to besupported at its opposite end by chains 29 trained over sprockets 29aaffixed to opposite ends of an equalizer shaft 30. The chains 29 alsosupport counterweights 31, which are intended to provide a substantiallyneutral counterbalance to the entire floating roll mechanism. The endextremities of the shaft 32 of the floating roll are guided in avertical slot 33 (FIG. 1B) which confines the movement of the floatingroll and guides it in a vertical plane.

To provide a controlled downward weight bias on the floating roll 24, arod 34 is pivoted at 35, at one side of the supply stand, and isconnected at the other end to one side of the floating roll shaft 32 bymeans of a pivoted connecting link 35a. The rod 34 carries one or moreslidably adjustable control weights 36, which may be moved toward andaway from the pivot point 35 to adjust the effective weight applied tothe floating roll.

In this connection, although the adjustable weight is ap-.

plied at one side only, its effect is balanced because of the equalizershaft 30. A suitable chain and sprocket.

arrangement, generally designated by the numeral 37, connects theequalizer shaft 30 to the rotary control device 28, so that a positiverelationship is maintained between the vertical position of the floatingroll and the.

rotary position of the control device 28. The rotary control device doesnot significantly alter the forces balancing the floating control roller24, so that the fabric supplied from the feeding device of FIG. 1B is atall times under a substantially uniform tension, which is maintained atthe lowest practicable amount.

Suitable limit switch means (not shown) may be provided to shut down theentire line in the event that the floating roller 24 would move toeither the upper or lower limit of travel provided by the slot 33,reflecting a malfunction of the system at some stage. In addition, it isdesirable to support the initial idler roll 21 to accommodate a limiteddownward movement in response to excessive tension in the fabric leadingfrom the supply. Such movement is utilized to trip a safety switch 21a,to shut down the entire line.

Referring now to FIGS. 1A and 3, the numeral 40 designates a framestructure for the processing section of the system of the inventionwhich supports the edge drive rolls, the steamer and the calender rolls.At the upstream or entry side of frame 40 there are provided brackets41, which support a pair of guide rods 42, 43 extending traverselyacross the machine frame. The guide rods support a pair of edge driveroll carriages 44, 45, on which are supported, for rotation aboutvertical axes, a pair of edge drive rolls 46, 47.

A square or splined shaft 48 is journalled in the brackets 41, extendsthrough the carriages 44, 45, and mounts a sprocket 49 at one end. Thesquare shaft 48 is driven by a chain 50 from an adjustable speed motor51. To advantage, the speed of the motor 51 is controlled by the machineoperator, using conventional controls (not specifically illustrated)such that adjusted speed of the edge drive rolls constitutes the basicmachine speed of the system, and all other speed functions areappropriately related thereto. By way of example, the operational speedof the infeed station automatically is relatedto the adjusted speed ofthe edge drive rolls by means of the modulating control of the floatingroller 24, which continually senses the rate at which the fabric isbeing demanded by the edge drive rolls 46, 47.

Positioned between the edge drive rolls 46, 47 is a spreading framedesignated by the reference numeral 52. This spreading frame typicallyincludes a pair of frame sections 53, 54 extending longitudinally inspaced relation, and an adjusting bar 55; which connects the two framesections, advantageously in the region of the edge drive rolls, andholds them at a predetermined width dictated by the fabric processingrequirements.

When the equipment is to be operated as a tensionless calender (see Cohnet al., US. Pat. Nos. 2,589,344 and No. 2,589,345, for example), thespreader frame 52 includes a pair of upstream propeller belts 56, and apair of downstream propeller belts 57, guided by a plurality of rollers58, so as to have longitudinally extending portions exposed at the outeredge extremities of the spreader frame for engagement with the internaledges of the length of tubular knitted fabric distended over the frame.

The respective pairs of belts 56, 57 are trained over drive pulleys 59,60 located in the mid-region of the spreader frame. The drive pulleysare arranged to be positioned in straddling relation to the edge driverolls 46, 47 and to contact the rolls through an interposed wall offabric. Thus, when the edge drive rolls are rotated, by the square driveshaft 48, the respective propeller belts 56, 47 are driven by thepulleys 59, 60. By appropriate design of the pulleys 59, 60, theupstream belts 56 are caused to operate at a slightly higher rate ofspeed than the downstream belts 57, so that the tubular knitted fabricis slightly overfed onto the downstream belts. This accommodateslengthwise relaxation of the fabric.

The two-stage spreader can also be arranged to underfeed the fabric fromthe first to the second stage, if desired. Where the equipment is to beoperated so as a so-called straight line calender, the spreader framemay employ a single pair of belts arranged to convey the fabric atconstant speed over the full length of the spreader.

Proper entry of the unprocessed tubular knitted fabric 12 onto thespreader frame is promoted by an entry end guide bar assembly 61. Theguide bar assembly includes at each side a rod section 62 which isreceived in a pivotable socket 63 carried at the upstream extremity ofthe spreader frame. The rod sections 62 are connected to second rodsections 64 by short springs 65, which accommodate bending actionbetween the first and second rod sections. The respective rod sections64 are in turn connected together by a spring 66, which likewiseaccommodates bending action between those rod sections. The entireassembly is covered by a section of plastic tubing 67, so that theincoming fabric freely slides over the guide bar and is advanced to thepropeller belt sections of the spreading frame. The describedconstruction of the entry guide bar assembly is advantageous in that itaccommodates substantial variation in the spacing of the spreader framesections 53, 54 by the bending action of the springs 65, 66 and thepivoting movement of the sockets 63.

In accordance with one aspect of the invention, transverse adjustment ofthe edge drive roll carriages 44, 45 is effected by means of a threadedshaft 70, which is reversely threaded at opposite ends so as to effectsimultaneous and equal inward or outward movement of the respectivecarriages 44, 45 upon rotation. In accordance with the invention, thethreaded shaft 70 is not directly threadedly connected to the carriages44, 45. Rather, there are provided drive nuts 7!, 72 which have threadedengagement with the shaft 70 and which are connected to the respectivecarriages 44, 45 through a plurality of bolts 73 and compression springs74. The springs 74 normally are precompressed so as to urge thecarriages away from the drive nuts, in a transversely inward direction,until the bolt heads 75 are seated against the outer surfaces of thedrive nuts.

For driving the threaded shaft 70, there is advantageously provided astallable drive motor, such as a stalltorque electric motor or, morepreferably, a low torque air motor 76. The air motor 76 is actuated bymeans of a reversing valve 77 and a variable pressure regulator valve78. Thus, when the valve 77 is actuated to advance the edge drive rollcarriages 44, 45 in a closing direction, it will continue to operateuntil the edge drive rolls have engaged the spreader frame 52 throughthe fabric walls, and the threaded shaft 70 has met with sufficientresistance to further rotation to cause the air motor 76 to stall out.The amount of torque resistance required to effect such stalling iscontrolled by the variable pressure regulator 78.

A substantial advantage is realized in actuating the carriages 44 or 45through the compressible springs 74 rather than directly from thethreaded shaft 70, in that inertia effects of the closing movement canbe to large extent absorbed by a slight amount of compression in thesprings. Likewise, minor irregularities in the fabric can beaccommodated between the spreader frame and the edge drive roll byslight compression of the springs, without significantly increasing themomentary edge pressure of the fabric. To even greater advantage, it isfeasible to provide a great degree of operator control over fabric edgepressure by providing a calibrated indicating device to reflect theamount of compression in the springs 74. Thus, as shown in FIG. 5, thedrive nut 71 may be provided with a series of calibrating marks 79associated with a fixed mark 80 carried by an indicator bracket 81extending from the carriage 44. When the edge drive rolls are advancedinto position, the spring 74 will be compressed a predetermined amountbefore the motor 76 stalls out. The extent of the spring compressionwill be reflected by the relationship of the calibration marks 79, 80and this will accurately reflect the amount of the edge pressure on thefabric. The machine operator may then easily adjust the pressureregulating valve 78 to achieve a desired degree of edge pressure asreflected by the calibrating marks.

On occasion, the incoming fabric 12 may tend to jam at the upperextremity of the spreader frame (as, for example, if the fabric werebadly twisted or torn In such cases, the driving forces on the fabricmay dislodge the spreading frame with the potential of casing damage tothe equipment. In accordance with the present invention, thiseventuality is effectively prevented by providing a safety limit switch82, mounted on one of the carriages 45 (FIG. 4) by means of a suitablebracket 83. The safety switch 82 cooperates with an actuating arm 84carried by the associated drive nut 72. One or both of the switch andactuating lever 82, 83 are positioned to provide for the switch to be ina dc-actuated" condition during normal operations of the equipment.However, should the fabric 12 snag at the entry end of the spreaderframe, dislodging the spreader frame, the edge roll cases will be movedquickly inward by the springs 74, causing the switch 82 to be actuated.By appropriate circuit arrangement (not shown but readily providable bypersons skilled in the art) actuating of the safety switch 82immediately shuts down the entire line for correction of themalfunction.

As will be appreciated, when the edge drive rolls 46 and 47 arewithdrawn from the spreader frame, the frame will drop downward unlessindependently supported. Normally, the downstream extremity 85 of thespreader frame extends at least slightly between the rolls 86, 87 of thecalendering stage. so that some support is provided for this end of theframe. For support of the upstream end of the frame, it is advantageousto provide a support bar 88 which is pivotally mounted on the machineframe by swing arms 89. Normally, the bar 88 rests in a position spacedbelow the spreader frame, to be out of contact with the fabric passingthereover. However, in preparation for separating the edge drive rollsand releasing the frame, the support bar 88 is swung to its upwardposition, shown in phantom lines in FIG. IA, and secured by a latch 90.

To great advantage, the system of the present invention incorporates anew and improved steaming facility which is the subject of copendingapplication Ser. No. 355,40l, filed Apr. 30, I973, entitled HighProduction Steamer." This steamer, generally designated by the numeral14 in FIG. 1A, is described in detail in said copending application andreference thereto may be made for supplemental information. In general,the steaming apparatus 14 includes a pair of dripless steam boxes 91, 92extending transversely across the width of the fabric above and belowthe plane of the spreader 52. The construction of these steam boxes maybe substantially in accordance with the S. Cohn et al., U.S. Pat. No.2,602,314, granted July 8, 1952.

As reflected in FIG. 6, the steam boxes 91, 92 may be of similarconstruction, although reversely oriented, to provide pairs oftransversely extending steam discharge slots 93. Perforated steam inletpipes 94 extend across the width of the steam boxes are arranged todischarge steam toward the closed side of a U-shaped channel 95. Flangedlips 96 of the channel extend toward the steam pipes and provide for theegress of steam into the main chamber of the steam box formed by anouter casing 97. In the case of the upper steam box 91, condensate iscollected in the bottom of the channel 95, draining through an endopening 98 and eventually being extracted through an outlet pipe 99. Inthe case of the lower steam box, condensate is collected in troughsformed by the flange lips 96, enabling the condensate to be drainedtowards the ends of the steam box and eventually to be extracted throughan outlet pipe 100. The outer housing 97 has flanged lips 101 whichextend alongside the outer walls of the interior channel 95, to providenarrow, vertically extending slots 93 for the discharge of steam to theoutside. The configuration of these slots 93 is such that steamcondensate in the outer casing 97 of the upper box is collected introughs 102 and eventually drained through outlet pipe 99.

The arrangement of the steam boxes is such as to enable steam to bedischarged in full width jets across the width of the fabric both fromabove and from below the plane of the fabric. At the same time,condensate formed internally of the steam boxes is trapped and preventedfrom dripping on the fabric to cause spotting or staining. Desirably, atleast the upper steam box 91 is provided with thermal insulation 103.

Although the steam boxes constructed in accordance with thebeforementioned S. Cohn, et al. patent are highly effecient andeffective in operation, the steaming operation has constituted abottleneck" of the finishing stage operations performed on tubularknitted fabric. In this respect, it is desirable to impart predeterminedamounts of moisture to the fabric to enable the necessary fiberrelaxation and readjustment to occur. With equipment heretoforeutilized, efforts to increase the rate of production or increasing therate of steam application beyond a predetermined level have beenrelatively ineffective, resulting either in non-uniform application ofthe steam, or in excessive problems from condensation and spotting, orboth. In the system of the present invention, however, the fabricsteaming facilities include significant improvements enabling theeffective rate of steam to be greatly increased and production rates tobe correspondingly increased, up to as much as two to four times therate of production using conventional equipment.

In accordance with the present invention, the steam.

boxes 91, 92 are surrounded and substantially enclosed by a steamchamber 104. The chamber 104 includes an insulated upper wall 105extending over the top of the upper steam box 91, and insulated upperside walls 106, I07 extending downward at an angle and terminatingapproximately at the level of the bottom of the steam box 91. Thechamber also includes a bottom wall 108 disposed below the lower steambox 92, bottom side walls 109 and 110 extending upward at an angle fromthe bottom wall, and side wall extensions 111, I12 extending more orless vertically upward from the upper extremities of the bottom sidewalls and terminating approximately at the level of the top of the lowersteam box 92. End walls 113 connect the upper wall structure with thelower wall structure and form therewith a substantially totally enclosedsteam chamber having narrow transverse openings 1 14, 115 to accommodatethe spreader frame and the distended fabric being conveyed by the frame.Desirably, flexible seals 116, 117 are provided at the openings arrangedto conform to the operatively positioned spreader frame to substantiallyclose off the openings 114, 115 while permitting the free passage of thetubular knitted fabric through the chamber. Typically, the flexibleseals may take the form of soft brushes or the like. In this respect.highly effective sealing is not a requirement of the elements 116, 117,but some closure facility is preferred to guide and confine the flow ofsteam and air within and about the chamber.

As will be readily apparent in FIGS. 1A and 3, the width dimension ofthe steam chamber 104--that is, in the longitudinal direction of fabricmovement--is substantially less than the length of the spreader frame52. In the illustrated system, the upstream'todownstream dimension ofthe steam chamber is considerably less than the length of the second ordownstream stage of the spreading frame, and is also considerably lessthan the transverse dimension or length of the chamber.

As reflected in FIG. 6, the steam chamber 104 includes a baffle plate120, having a portion extending underneath the lower steam box 92, andflanges 121 extending upwardly and outwardly from the bottom portion.The baffle plate 120 is mounted by means of spacer posts 122 in spacedrelation with the bottom wall 108 and bottom side walls 109, 110 of thesteam chamber. The baffle plate 120 extends substantially to the endwalls 113 of the steam chamber, but its flanges 121 are spaced away fromthe vertical side walls 111, 112 of the chamber so as to form large,transversely elongated passage openings 123 on opposite sides of thelower steam box 92.

An exhaust duct 124 is connected to the bottom wall 108 of the steamchamber so as to be in communication with the flow passage formedbetween the baffle 120 and the adjacent walls of the chamber. Theexhaust duct is connected by suitable tubing 125 to the intake of anexhaust fan 126 arranged to direct the exhaust materials to anappropriate discharge point.

As will be understood from the illustration of FIG. 6, the exhaust duct124 provides for a downdraft exhaust flow of the steam atmospherecontained in the chamber 104. Thus, steam issued in high velocity jetsfrom the narrow openings 93 is impinged directly on the fabric passingthrough the chamber, disperses into the chamber at large, and then isquickly drawn downwardly through the passages 123 and exhausted throughthe duct 124. This arrangement of conventional steam boxes, closelyconfined within a steam chamber of limited volume in relation to thesteam boxes and provided with a highly effective exhaust facility,enables the rate of application of steam from the steam boxes to begreatly increased without undesirably affecting the processingoperation. More importantly, it significantly increases the rate atwhich the fabric may be effectively processed to a desired moisturecontent. Thus, high quality processing may be achieved at up to fourtimes the rates possible with conventional apparatus.

Most advantageously, the capacity of the exhaust blower 126 is sorelated to the rate of input of steam into the chamber 104 as tomaintain a substantially neutral to slightly positive pressure conditionwithin the chamber, thereby preventing the escape of excessive amountsof steam from the chamber, while also preventing the inflow ofundesirable amounts of fresh air. After passing through the steamchamber 104, the

fabric is directed through calendering rolls 86, 87,

which may or may not be closed, depending upon the 5 desired treatmentto be imparted to the fabric. Where the fabric is to be calendered, therolls 86, 87 are brought into closed, pressure-bearing relationship. Tothis end, the lower roll 87 may be journalled on a fixed axis in abearing block 130, while the upper roll 86 may be journalled in abearing block 131 arranged for vertically guided movement in a guideframe 132. To advantage, appropriate spring means (not shown) areprovided for biasing the movable bearings [31 and the upper calenderroll 86 to an upward or open position. The calender roll may be moveddownwardly, in opposition to the biasing springs, by means of fluidactuators 133 at each side, controlled by a pressure regulator 134.Thus, any degree of operating pressure may be applied to the nip ofrolls 86, 87 by appropriate adjustment of the pressure regulator 134. Inthe illustrated arrangement, the lower calendering roll 87 is drivendirectly by an electric drive motor 135, through a chain 136. The uppercalendering roll 86 is driven in synchronism with the lower roller bymeans of idler pinions 137, 138 mounted on suitable linkages (not shown)or otherwise arranged to maintain a constantly meshing relationshipwhile accommodating limited vertical movements of the upper roll 86.

The drive motor 135 for the calender rolls is speed adjustable relativeto the main drive motor 51 for the edge drive rolls. Thus, any change inthe speed of the edge drive rolls automatically will be reflected in thecalender rolls, although the latter may be separately adjusted,typically to run at a controllably lower rate of speed than the edgedrive rolls, to accommodate the overfeeding of the fabric where desired.

At the discharge end of the equipment there is provided a batching stand140, which includes a roll-up batcher for the processed fabric, as wellas fabric cutoff means and means for automatically or semiautomaticallycommencing the start of a new roll batch after fabric cut-off. Toadvantage, the batching stand may also include means for weighing thecompleted roll or batch, and also yardage counting means for recordingthe lengths of material in the successive batches.

Referring now to FIGS. 1A, 7 and 8, the batching stage includes a drivenwindup roller 141, which is journalled in the frame and is driven by avariable speed electric motor 142 by means of a chain 143 and suitablesprockets. To advantage, the variable speed motor 142 is controllable inrelation to the drive motor 135 for the calender rolls. Thus, anyvariation in calender roll speed automatically will be reflected by acorresponding speed change in the windup roll motor 142. In addition,however, the motor 142 may be adjusted to operate at a certainpercentage of speed above or below the speed of the calender drive motor135. The arrangement typically is such that the fabric 145 extendingbetween the calendering stage and the windup stage 16 is maintainedunder a very slight tension, sufficient to maintain the fabric undercomplete control without, however, introducing an excessive degree oflongitudinal tension.

Pivotally mounted on the batching stand 140 is a support bracket 146,comprising a pair of support arms at each side of the machine, pivotedby a shaft 147 and secured together by suitable bracing (not shown) formovement in unison. The bracket 146 is operatively connected to a fluidactuator 152 for pivoting movement about an angle of almost 90, from theposition shown in full lines in IA and 7, to the position shown inphantom lines in FIG. 7.

Secured to the bracket 146 are opposed pairs of mandrel guiding channels148 and 149. The channels 148 constitute the principal mandrel guides,while the channels 149 form a reservoir for a new mandrel, beingprovided with an upwardly opening slot 150 in which a new mandrel may beplaced during the winding ofa roll of fabric on a previous mandrel. Inoperation, a mandrel 151 of appropriate length and diameter is receivedin the main guide channel 148 and arranged to bear against fabricresting on the driven winding roll 141. After starting of the windupoperations, by means to be described, the accumulating roll forces themandrel 151 radially away from the windup roll, urging it upward in theguide channels 148, until the desired roll size has been reached, asreflected in FIG. 1A. At that point, the actuator 152 can be energizedand extended to pivot the bracket 146 in a counterclockwise direction,to a position in which the guide channels 148 are tilted slightlydownward. The completed roll of fabric then is readily rolled downhill,while still supported by the end of the mandrel 151, until the mandrelends drop into V-shaped receiving troughs 153 at the end of the windupstand 140. When this pivoting action take place, a new mandrel, held inthe feeder channel 149, rolls down and enters the main guide channel 148behind the fully wound fabric roll and rests there, are reflected at151a in FIG. 7. When the bracket 146 subsequently is pivoted clockwiseback to its normal position, the new mandrel 151a slides down the mainguide channel 148, to rest directly on the fabric passing over thewinding roll 141.

In the apparatus of the invention, a cut-off facility is provided on thedownstream side of the winding station. This comprises a pair oftransversely extending, opposed guide channels 160, 161 (FIG. 8) whichserve to support and guide for transverse movement a cutter carriage162. The carriage mounts a rotary cutting knife 163 driven by anelectric motor 164. The cutter carriage has a plurality of guide rollers165 arranged to engage the channels 160, 161 internally and accommodatethe high speed travel of the cutter carriage across the full width ofthe machine. A drive cable 166 is connected to the carriage 162 by meansof a bracket 167. The drive cable passes around pulleys 168 at each sideof the machine and is connected to a moving piston element 169 within anelongated air actuator 170. When air is introduced into the left handend of the actuator, as illustrated in FIG. 8, the cutter carriage israpidly driven toward the left across the machine. When the cuttercarriage engages a traverse limit switch (not shown), at the extremityof its movement, it energizes a carriage traverse timer. At the end ofan adjustable delay period. the air supply to the actuator 170 isreversed, and the cutter automatically returns to its starting position.Typically, the cutter motor 164 is electrically driven and, for thispurpose, a retractable power cord 172 extends from an automatic rewinddevice 173 secured at the side of the windup frame 140.

In typical operation of the equipment, when a fabric roll has achievedthe desired size, the machine operator stations himself at the dischargeend of the machine (left hand end, as viewed in FIG. 1A) to prepare forthe cut-off and restarting operations. When he desires to remove thecompleted roll, the operator actuates a foot switch 180, which isaccessible from his station at the end of the machine. This causes theentire line to be stopped or at least slowed down to a very low speed.At the same time, the fluid actuators 152 are energized to pivot theroll support brackets 146 in a counterclockwise direction to theposition shown in phantom lines in FIG. 7. The fabric roll will thentend to travel down the path formed by the downwardly inclined guidechannels 148, but typically this movement is expedited by the operatormanually gripping the exposed ends of the mandrel 151 (see FIG. 8) anddrawing the completed roll toward the end of the machine. As the mandrel151 reaches the end of the guide channel 148, it drops into the V-shapedreceiving sockets 153 initiating further operations. When the mandrelends are in their receiving sockets, a switch 181 associated with one ofthe sockets is actuated. The fluid actuator 152 is thereby reversed toswing the brackets 146 and guide channels 148 clockwise back to theirnormal operating positions. After the guide channels 148 have returned,and thus cleared the path of the cutter assembly 162-165, a timingswitch (not specifically illustrated) functions to energize the traversecylinder and initiate a rapid cutting traverse of the cutter carriage.The tubular fabric will at this time be draped over the guide channels160, 161, and the fabric thus will be severed by the cutter as itproceeds through its traverse, freeing the completed roll from theremainder of the fabric supply.

When the carriage reaches the end of its cutting stroke, it remainsthere until the traverse timer times out and initiates a returnmovement. During the short dwell of the carriage between cutting andreturn strokes, the cut end of the fabric is flipped over and restartedas a new roll, as will appear.

In accordance with one aspect of the invention, the entire cutterapparatus, including the carriage 162, its guide channels 160, 161, andthe related mechanisms is mounted on the arms of the pivotable bracket146. As a result, when the bracket 146 is pivoted to discharge a woundroll, the entire cutter assembly pivots with the bracket to its is thustemporarily retracted out of the way of the discharged roll. After thewound roll has been received in the sockets 153, the bracket 146 ispivoted back toits upright position, returning the cutter assembly toits operative position and orientation,

By providing for the momentary pivotal retraction of to locate thecutting system and the cutting line much higher and much closer to thewinding roll 14] than otherwise. This has the important advantage ofreducing to a practical minimum the length of the tail of fabric whichis to be flipped back over the new mandrel to start a new roll. Bykeeping this tall very short, greater reliability and uniformity isachieved in the restarting of rolls. In addition, the improvedarrangement better accommodates the winding and handling of rolls ofrelatively large diameter.

Upon return of the guide channels 148 to their upright position, the newmandrel 151a, having previously rolled into the channel 148, now rollsdown onto the winding roller 141, where it engages the layer of fabricextending over the winding roller in preparation for winding a new roll.In the following moments, the cutter carriage 162, as it completes itscutting traverse,

trips a limit switch (not shown) initiating the flow of air underpressure to a manifold pipe 190, extending transversely across themachine in the region between the driven windup roller 141 and thecutter traverse channels 160, 161. The manifold 190 has an elongateddischarge slot 191 extending therealong, which is directed upwardly andslightly rearwardly. When air is supplied to this manifold 190 the freecut end of the fabric is blown upwardly and rearwardly around the newlypositioned mandrel 151, coming to rest on the upper surface of thefabric, on the upstream side of the mandrel 151 as reflected at 192 inFIG. 7. The duration of air supply to the pipe 190 advantageously iscontrolled by a timer.

When the cutter carriage reaches the end of its stroke, a rotaryactuator 193 is energized to pivot, in a counterclockwise direction, apair of tuck-in arms 194. These arms, which are of L-shapedconfiguration, carry positioning rollers 195 at their free ends, whichare arranged to engage the end extremities of the newly positionedmandrel, to both serve as a position stop for the tuck-in arms 194 andmomentarily to apply a controlled amount of pressure to the mandrel.Such momentary pressure helps to avoid slippage of the fabric on thedriven winding roller 141 during the startup of a winding sequence whenthere is little or no inherent to the newly started roll.

Secured to the tuck-in arms 194, and extending across the width of themachine, is a tuck-in bar 196. The tuck-in bar has a plurality ofresilient tucking fingers 197 so positioned that, when the arms 194 areactuated to their counterclockwise limit positions, the fingers engagethe loose upper flap of the fabric 192, in the region of the bightbetween the mandrel 151 and the winding roller 141, and cause a portionof the fabric to be tucked into this bight. The combination of thistucking, in cooperation with the controlled momentary pressure appliedby the positioning rollers 195, provides for controllably reliablerestarting of the winding operation, after cut-off and doffing of acompleted batch. The flip-over and tuck-in operations are normallyinitiated while the processing line remains in a stopped or slow speedcondition. However, by appropriately located limit switch means (notshown) the counterclockwise movement of the tuck-in arms 194 tooperative positions serves to reactuate the processing line to resumeits normal forward speed.

To advantage, the clockwise or return movement of the tuck-in arms isunder the control of an appropriate time delay means, coinciding withtimed return of the cutter carriage, enabling the tuck-in operation tobe reliably and effectively carried out, while at the same timewithdrawing the tuck-in bar 196 before the newly winding roll undergoesa significant increase in diameter.

The completed roll batch, now resting in the sockets 153, may be removedand carried away during the interval of the winding of the nextsuccessive roll, as will be appreciated. When the filled mandrel 151 isreceived in the socket 153, it is also automatically weighed. Thespecific facility for registering the weight is not critical. Toadvantage, however, it may be an appropriate strain gauge or transducerselement (not shown) which will sense the weight of the ends of themandrel 151 when resting in the sockets 153.

The apparatus of the invention provides a highly improved form ofapparatus for carrying out calendering and finishing operations ontubular knitted fabrics. While the finishing operations themselves areessentially conventional in a general sense, involving lateraldistending, overfeeding (if desired) for lengthwise relaxation,steaming, calendering and batching, the man ner in which theseoperations are accomplished with the apparatus of the invention resultsin important advantages including significantly increased productionspeeds. ln particular, the processing speed of conventional steamfinishing equipment has been inherently limited by the ability to carryout the steaming operation effectively. Thus, in the steaming operationa desired amount of moisture must be imparted to the fabric withoutcausing water spotting or other blemishes on the fabric. Heretofore,efforts to increase production speeds by increasing the volume and/orvelocity of steam application have not met with success, partly becausethe ability to impart moisture to the fabric does not appear to besimply a function of velocity of steam and partly because of severespotting problems from condensing moisture. With the system of thepresent invention, however, by effecting the application of steam to thefabric with steam jet means located within a confining chamber closelyembracing and surrounding the steam outlet means, and continuouslyextractly excess steam from the enclosed chamben'the effectiveproduction rate of the steaming operation can be greatly increasedrelative to conventional speeds without compromising production qualitystandards.

The upstream" portions of the new system may be utilized with variousbatching means, including folders. Nevertheless, the system of theinvention incorporates to advantage improved yet simplifiedsemi-automatic facilities for windup batching and doffing of the fabric.with a minimum of operator attention and with a minimum of discontinuityin the operation of the equipment. Thus, when the batch roll has reachedthe desired size, the operator initiates the doffing sequence by meansof a simple foot switch control, after which roll removal, fabriccut-off, and restarting operations are carried out in a rapid, automaticsequence without further operator intervention. To this end, a novelmechanism is provided for tucking in the cut-off fabric end and forapplying momentary starting pressure to the new mandrel for effectivelyreliable restarting of the windup. Once a few turns of fabric have beenmade upon the new mandrel, the rewinding will continue unaided, and thetuck-in element and the axiliary pressure means may be quicklyretracted.

At the entry end of the machine, greatly improved arrangements areprovided for the lateral positioning and control of the edge driverolls, to simplify the operators task and to enable him to exercisegreater control over the operating procedures. in this respect, the edgedrive roll lateral adjustment is carried out through drive nuts engaginga threading positioning shaft and acting upon the edge drive rollcarriages through compressible spring means. A desired level of edgedrive roll pressure is achieved by a desired degree of springcompression, affording a much more delicate control over edge pressureon the fabric than if the edge drive carriages were themselves connecteddirectly to the threaded positioning shaft. Initial movement of the edgedrive rolls into gripping relation with the propeller frame is achievedby actuation of a stallable motor, advantageously an air motorcontrolled by a pressure regulator to stall out at a desired level oftorque resistance on the threaded shaft. The amount of edge pressure isreflected by the extent of spring compression, and this in turn can bereadily and accurately reflected by a calibrated indicator extendingfrom one or both of the edge drive roll carriages to the associateddrive nut therefore.

The system of the invention also incorporates an improved fabric supplysystem which is uniquely advantageous in the finishing operation. Thus,the supply stand illustrated in F105. 1B and 2 is independently speedcontrolled by the floating roller 24, which maintains a predeterminedrunning reserve of fabric substantially without varying the longitudinaltension of the incoming fabric. With this arrangement, greateruniformity in the relaxation and stabilization of the fabric can berealized than would be the case where movement of the floating rollerwas accompanied by a change in the force imparted thereby to the fabric.

It should be understood, of course, that the specific form of theinvention herein illustrated and described is intended to berepresentative only, and any changes may be made therein withoutdeparting from the clear teachings of the disclosure. Accordingly,reference should be made to the following appended claims in determiningthe full scope of the invention.

1 claim:

1. A system for the treatment of tubular knitted fabric and includingdriver means for spreading the fabric to predetermined width, means forsteaming the spread fabric, and means for gathering the spread andsteamed fabric after discharge from the spreading means, characterizedby a. edge drive rolls mounted at opposite sides of the spreading meansfor engaging and driving the spreading means through the edge walls ofthe fabric,

b. power means for moving the edge drive rolls toward each other foreffecting pressure engagement between the edge drive rolls and thefabric edge walls, including threaded shaft means for moving the edgedrive rolls, and drive means for rotating said shaft means,

c. adjustable control means for automatically limiting the pressure ofengagement between the edge drive rolls and the fabric by disabling thedrive means when a predetermined pressure is established between theedge drive rolls and the fabric,

d. said drive means comprising an air driven motor,

and

e. said adjustable control means comprising a controllable pressureregulator associated with said air driven motor and effective to causesaid motor to stall when a predetermined edge pressure is achieved.

2. A system for the treatment of tubular knitted fabric and includingdriver means for spreading the fabric to predetermined width, means forsteaming the spread fabric, and means for gathering the spread andsteamed fabric after discharge from the spreading means, characterizedby a. edge drive rolls mounted on carriages at opposite sides of thespreading means for engaging and driving the spreading means through theedge walls of the fabric,

b. means for moving the edge drive roll carriages toward each other foreffecting pressure engagement between the edge drive rolls and thefabric edge walls,

c. said means for moving further including a controllably driventhreaded shaft,

d. a pair of drive nuts arranged in threaded engagement with said shaftand associated with the respective edge drive roll carriages,

e. spring means interposed between the associated drive nuts and edgedrive roll carriages, whereby rotation of said shaft effects movement ofsaid drive nuts and, through the interposed spring means, also of saidedge drive roll carriages, and

f. edge drive pressure indicator means comprising an indicator devicecarried by one element of an associated edge drive roll carriage anddrive nut pair, and

g. calibration scale carried by the other element of the associatedpair,

h. the position of said indicator in relation to said scale reflectingthe magnitude of the edge drive roll pressure.

3. A system for the treatment of tubular knitted fabric and includingdriver means for spreading the fabric to predetermined width, means forsteaming the spread fabric, and means for gathering the spread andsteamed fabric after discharge from the spreading means, characterizedby a. edge drive rolls mounted on carriages at opposite sides of thespreading means for engaging and driving the spreading means through theedge walls of the fabric,

b. means for moving the edge drive roll carriages toward each other foreffecting pressure engagement between the edge drive rolls and thefabric edge walls,

c. said means for moving further including a controllably driventhreaded shaft,

(1. a pair of drive nuts arranged in threaded engagement with said shaftand associated with the respective edge drive roll cariages,

e. spring means interposed between the associated drive nuts and edgedrive roll carriages, whereby rotation of said shaft effects movement ofsaid drive nuts and, through the interposed spring means, also of saidedge drive roll carriages,

f. a safety limit switch operatively associated with a drive nut and itsassociated edge drive roll carriage,

g. said safety limit switch being operative in response to apredetermined condition of compression of said spring means to stopoperation of the treating system.

1. A system for the treatment of tubular knitted fabric and includingdriver means for spreading the fabric to predetermined width, means forsteaming the spread fabric, and means for gathering the spread andsteamed fabric after discharge from the spreading means, characterizedby a. edge drive rolls mounted at opposite sides of the spreading meansfor engaging and driving the spreading means through the edge walls ofthe fabric, b. power means for moving the edge drive rolls toward eachother for effecting pressure engagement between the edge drive rolls andthe fabric edge walls, including threaded shaft means for moving theedge drive rolls, and drive means for rotating said shaft means, c.adjustable control means for automatically limiting the pressure ofengagement between the edge drive rolls and the fabric by disabling thedrive means when a predetermined pressure is established between theedge drive rolls and the fabric, d. said drive means comprising an airdriven motor, and e. said adjustable control means comprising acontrollable pressure regulator associated with said air driven motorand effective to cause said motor to stall when a predetermined edgepressure is achieved.
 2. A system for the treatment of tubular knittedfabric and including driver means for spreading the fabric topredetermined width, means for steaming the spread fabric, and means forgathering the spread and steamed fabric after discharge from thespreading means, characterized by a. edge drive rolls mounted oncarriages at opposite sides of the spreading means for engaging anddriving the spreading means through the edge walls of the fabric, b.means for moving the edge drive roll carriages toward each other foreffecting pressure engagement between the edge drive rolls and thefabric edge walls, c. said means for moving further including acontrollably driven threaded shaft, d. a pair of drive nuts arranged inthreaded engagement with said shaft and associated with the respectiveedge drive roll carriages, e. spring means interposed between theassociated drive nuts and edge drive roll carriages, whereby rotation ofsaid shaft effects movement of said drive nuts and, through theinterposed spring means, also of said edge drive roll carriages, and f.edge drive pressure indicator means comprising an indicator devicecarried by one element of an associated edge drive roll carriage anddrive nut pair, and g. calibration scale carried by the other element ofthe associated pair, h. the position of said indicator in relation tosaid scale reflecting the magnitude of the edge drive roll pressure. 3.A system for the treatment of tubular knitted fabric and includingdriver means for spreading the fabric to predetermined width, means forsteaming the spread fabric, and means for gathering the spread andsteamed fabric after discharge from the spreading means, characterizedby a. edge drive rolls mounted on carriages at opposite sides of thespreading means for engaging and driving the spreading means through theedge walls of the fabric, b. means for moving the edge drive rollcarriages toward each other for effecting pressure engagement betweenthe edge drive rolls and the fabric edge walls, c. said means for movingfurther including a controllably driven threaded shaft, d. a pair ofdrive nuts arranged in threaded engagement with said shaft andassociated with the respective edge drive roll cariages, e. spring meansinterposed between the associated drive nuts and edge drive rollcarriages, whereby rotation of said shaft effects movement of said drivenuts and, through the interposed spring means, also of said edge driveroll carriages, f. a safety limit switch operatively associated with adrive nut and its associated edge drive roll carriage, g. said safetylimit switch being operative in response to a predetermined condition ofcompression of said spring means to stop operation of the treatingsystem.